Foaming compositions



United States Patent Ofilice 3,364,154 Patented Jan. 16, 1968 I El 3,364,154 FOAMING CGMPQSITIONS Thomas Gilchrist, Prestwick, Scotland, and Mirlro Ternbah, Eeloeil, Quebec, Canada, assiguors to Canadian Industries Limited, Montreal, Quebec, Canada, a corporarion of Canada No Drawing. Filed Mar. 5, 1965, Ser. No. 437,587 Claims priority, apph'cation Canada, Aug. 18, 1964, 09,795 8 Claims. (Cl. 26)2.5)

ABSTRACT 6F THE DISt'JLQSURE Foamed cellular polymeric materials formed by a foaming reaction wherein a mixture of two dihydropyranyl compounds is polymerized in the presence of volatile foaming agent. The first dihydropyranyl compound is characterized by having its dihydropyranyl groups linked by an ester group. The second dihydropyranyl compound is an aldol condensation product of a dihydropyran carboxaldehyde. The combination of the two types of dihydropyranyl compounds provides cellular materials having properties superior to those of cellular materials derived from either compound alone.

This invention relates to improved compositions suitable for the production of foamed cellular polymeric materials and to improved foamed cellular polymeric materials obtained therefrom.

In Canadian application Ser. No. 873,718 filed by W. D. S. Bowering, N. B. Graham and J. l3. Murdock, on Apr. 20, 1963, there are described foamable compositions of a novel type which comprise at least one polymerizable vinyl ether containing at least two vinyl groups per molecule, a foaming agent, an acidic catalyst and, optionally, at least one compound reactive with said vinyl ether such as a polyhydric phenol, an aliphatic polyhydric alcohol, an epoxidized material, a polycarboxylic acid, a polyamide, a polycarbamate or an afimonoethylenically unsaturated compound. The compositions yield foamed cellular polymeric materials which are superior to the known polyurethane and polystyrene foams in many respects.

In spite of their many useful properties, however, foams made from some of the vinyl ethers tend to be very brittle. For example, a foamable composition comprising 3,4 dihydro 2H pyran-Z-methyl-(3,4-dihydro- ZH-pyran-Z-carboxylate), a foaming agent and an acidic catalyst yield a brittle charred foam which breaks down after a few days exposure to boiling water. When the vinyl ether employed in combination with a foaming agent and an acidic catalyst is the aldol condensation product of 2-formyl-3,4-dihydro-2H-pyran, the resulting foam is extremely brittle and weak although it has good hydrolytic stability. For commercial applications, it is desirable that the foams possess hydrolytic stability and resiliency, and flow readily during the foaming process.

It has now been found that foamable compositions comprising a combination of a cyclic vinyl ether wherein dihydropyranyl radicals are linked by ester groups and a cyclic vinyl ether which is the aldol condensation prodnot of a dihydropyran carboxaldehyde, yield foams which are both hydrolytically stable and flow readily. The addition to the ethers of materials such as polyhydric phenols, chlorinated phenols, carboxylic acids, polyols, polyepoxides, mono vinyl derivatives or organic polyisocyanates results in foams which are resilient in addition to possessing hydrolytic stability.

It is therefore the primary object of this invention to provide improved foamable compositions and improved foamed cellular polymeric materials based on polymerizable vinyl ethers containing at least two vinyl groups per molecule optionally admixed with vinyl ether-reactive compounds. Another object is to provide such foamed cellular polymeric materials having the desirable properties of hydrolytic stability and convenient foaming characteristics. Additional objects will appear hereinafter.

The foamable compositions of this invention comprise, (1) at least one polymerizable cyclic vinyl ether containing dihydropyranyl radicals linked by ester groups, (2) at least one polymerizable cyclic vinyl ether constituted by the aldol condensation product of a dihydropyran carboxaldehyde, (3) a catalyst, (4) a foaming agent and, optionally, (5) a vinyl ether-reactive compound. The chemical interaction of the ingredients of said compositions produce the improved foams of this invention.

The foamable composition of this invention may also include flame retardants, surfactants, dyes, fillers, stabilizers, antioxidants, plasticizers and viscosity modifiers.

The polymerizable vinyl ethers suitable for use in the foamable compositions are (1) those in which two or more dihydropyranyl groups are linked by ester linkages and (2) those formed by an aldol-type condensation of two or more dihydropyran carboxaldehydes. Dihydropyranyl compounds of these types are described in US. Patent Nos. 2,481,377 and 2,537,921 and in British Patent No. 770,381 and examples thereof are 3,4-dihydro- 2H pyran 2 methyl-(3,4-dihydro-2H-pyran-2-carboxylate) I and 2(2-formyl-3,-4-dihydro-l,2pyranyl)2- (3,4-dihydro-1,2-pyranyl) carbinol lI, having the following formulae The hydrogen atoms in the pyranyl rings may be replaced by substituent groups but it is not desirable to have more than one carbon atom adjacent to the dihydropyranyl double bond hearing such substituent groups.

A preferred aldol-linked dihydropyranyl compound is the trimer formed by the aldol condensation of 2-formyl- 3,4-dihydro-2H-pryan at 30 C. in the presence of sodium hydroxide catalyst. It is believed that said trimer is a mixture of trimeric condensation products, the main ones being:

and

One mole of 2-formyl-3,4-dihydro-2H-pyran can be obtained from each mole of the freshly prepared trimer by distillation at 60 C. under pressure of 14 mm. of mercury.

The catalysts suitable for promoting the reactions of the polymer-forming ingredients of the foamable compositions may be either acidic or non-acidic and include all catalysts capable of accelerating the reaction of vinyl ethers with compounds containing active hydrogen atoms.

The acidic catalysts suitable for promoting the reactions include the strong proton donating acids, such as p-toluenesulphonic acid, and the Lewis acids such as trimethoxyboroxine and borontn'fluoride conveniently employed as the etherate, BF (C H O.

Other materials which are suitable as acidic catalytic ingredients are ferric chloride, stannic chloride, phosphorus pentachloride, phosphoric acid, perchloric acid, acetic acid, trifluoro acetic acid, trichloro acetic acid, fiuoboric acid, borontrifluoride dihydrate, hydrogen fluoride, antimony pentafiuoride, hexafluorophosphoric acid, lead fluoborate, antimony fiuoborate, fluosilicic acid, sulphuric acid and silicotungstic acid.

Examples of suitable non-acidic catalysts include iodine and iodine containing compounds such as iodine chloride, iodine bromide, iodine perchlorate, iodine acetate, iodine triphosphate, and iodine triacetate; triphenylmethyl derivatives of anions having a low ester forming tendency, for example, triphenyl-methylperchloride, hexachloro antimony, chloromercurate, chlorozincate and chloroaluminate; alkyl, acyl and aroyl perchloride and hexachloro antirnonates such as tertiary butyl, acetyl and benzoyl compounds; and di azonium salts such as diazoniumchloride, fluoborate and hexachloro antimonates.

It is possible to control the polymerization reaction by employing catalyst combinations for example, p-tol enesulphonic acid and boron tn'fluon'de or boron tn'iluoride and trimethoxyboroxine. When Lewis acids are used as catalysts in foaming compositions devoid of phenolic, alcoholic or carboxylic acid ingredients, it is often advantageous to incorporate into the compositions small amounts of co-catalysts such as water, alcohols or carboxylic acids.

Volatile foaming agents suitable for use in the foamable compositions of this invention are those which are soluble or dispersible in the other ingredients of the foamable compositions, and are sufiiciently volatile that they vaporize during the formation of the foamed polymeric materials. The heat of the catalyzed polymerization reaction causes the foaming agent to boil and the vapour forms bubbles which expand during the polymerization reaction to give a low density foamed polymerized mass. Preferred foaming agents are the halogenated hydrocarbons such as trichloromonofluoromethane, dichlorotetrafluoroethane, trichlorotrifluoroethane, dibromodifiuoromethane, dichlorohexafiuorocyclobutane, methylene chloride, chloroform, trichloroethylene, carbon tetrachloride and perchloroethylene.

The vinyl ether-reactive compounds suitable for use in the compositions of this invention include polyhydric phenols such as resorcinol, phloroglucinol, cathecol, hy-

and 2:2 di p-hydroxyphenyl propane; polycarboxylic I acids such as succinic, adipic, azelaic, maleic, fumaric, itaconic, phthalic, isopht-halic, t-phthalic, trimellitic, trimesic and chlorendic acids and polymerized unsaturated fatty acids such as dimer and trimer acids; polyamides such as the di-amide derived from dimerized linseed oil acids and the polyamide derived from isophthalic acid and pentamethylene diamine; u,/8-monoethylenically unsaturated compounds such as 3,4-dihydro-2H-pyran, 2- ethoxy 3,4-dihydro-2H-pyran, 2-alkyl-3,4-dihydro-2H- pyran, 2-phenyl-3,4-dihydro-2'H-pryan, l-decene, vinyl stearate, lauryl vinyl ether, dibutyl maleate, maleic anhydride, vinyl cyclohexene, alkyl acrylates, alkyl meth-.

acrylates and styrene; and organic polyisocyanates such ,as tolylene 2,4-diisocyanate, mixtures of tolylene 2,4- and 2,6-diisocyanates, diphenylmethane diisocyanate, 4,4'-diisocyanate-3methyl-diphenyl methane, mand p-phenylene diisocyanates and chlorophenylene-2,4-diisocyanate.

Suitable flame retardants for incorporation in the foamable compositions include trichloroethylphosphate, tris(dibromopropyl) phosphate, 2:2-bis-(3',5-dibrorno- 4-hydroxyphenyl) propane, chlorendic acid, brominated castor oil, and polyvinyl chloride, with or without anti mony oxide. The phenolic compound and the chlorendic acid serve both as flame retardants and vinyl ether-reactive materials.

The preferred surfactants are those of the silicone type, examples of which are disclosed in Belgian Patents Nos. 582,362 and 584,089 being of the siloxane oxyalkylene copolymer type.

The relative proportions of the ester-linked dihydropyranyl compound to the aldol-linked dihydropyranyl compound in the compositions lie within the range of 10 to 1 and 1 to 10 by weight. The ingredients containing dihydropyranyl groups together may make up from 40 to 98% by weight of the foamable compositions and the foaming agent is present in amounts between 2% and 30% by weight of the compositions. The catalyst is employed in amounts between from 0.005% to 2.0% by weight of the compositions, but this proportion is adjustable to the temperature of operation and the foam induction period required. The vinyl ether-reactive compound may constitute up to 30% by weight of the compositions.

Foams prepared from compositions containing only the ester linked and aldol residue linked vinyl ethers as reactive ingredients have adequate flow properties but are hard and not resilient. The addition of up to 20% of a phenolic ingredient to these compositions improves the flow characteristics and yields a more resilient foam. Sometimes the foams from compositions containing a phenolic ingredient have friable skins. This effect can be eliminated by the addition of up to 25% of a polyhydric alcohol such as polypropylene oxide derivatives of a low molecular weight diols or polyols, or low molecular weight hydroxyl containing esters such as castor oil or diglyceryl tetrachlorophthalate.

It may be convenient to carry out the preparation of the foamable compositions in two stages, i.e., by first reacting a portion of the vinyl ether compound with the vinyl ether-reactive ingredient to form a prepolymer, this prepolymer being employed in conjunction with the remainder of the vinyl ether ingredient to carry out the foaming reaction,

The foams of this invention are hydrolytically stable and may be obtained either in rigid or resilient form. In a rigid form, the foams are eminently suited for heat insulation and sound absorption, either in closed cavities or 6 of 2-formyl-3,4-dihydro-ZH-pyran." During the preparation a part of the trichloromonofluoromethane is lost by evaporation so that the final product contains approximately by volume of trichlorornonofluoromethane.

as enveloping blankets. In the resilient form, they may be 5 Exam [8 1 used for upholstery, mattresses, etc. p

The ingredients of the foamable compositions may A homogeneous mixture was prepared from the followsimply be mixed by stirring in a vessel and then quickly lng Ingredients: 3,4-d-ihydro-2IIpyran-2-metthyl-(3,4-dipouring into a mould. In some cases it is convenient to hydro-ZH-pyran-Z-carboxylate), aldol trimer of 2-formylheat the composition in the mould to assist in the forma- 10 3, -dihyd 0-2H-pyran dissolved in trichloromonofluorotion of the foam. The foaming ingredients may also be methane 1n the proportions of 80/20 by volume, trichloromixed in the space which is to be filled with foam if it monofiuoromethane and siloxane oxyalkylene copolymer is suitably shaped. When such stirred mixing is used, it is type surfactant. A second homogeneous mixture was prehighly desirable that a surfactant be added to the compared contammg, in addition to the components of the positions in order to give foams of small bubbles. How- 19 first mixture, d1phenylmethane diisocyanate and the low ever, a surfactant is not always essential. For example, in molecular weight resinous condensate of epichlorohydrin certain foam dispensing machines, the ingredients are and 2:2-d1-p-hydroxyphenyl propane. To each mixture mixed under pressure using a foaming agent which is was added w1th vigorous stirring a portion of 10% solugaseous at the mixing temperature, the pressure being 9 tion of borontnfluoride etherate in diethylene glycol. The controllably released, and the frothed mixture is then discompos1t1ons and resulting foams are shown in Table I.

TABLE I v 0A A T w... Q 5 a as a a 8: s a s a a 5 es e 55 5 a A a e c :5 :iaa. n 555 5 as 758; 5 s5. '5? ar T, 3 ea a E193 gge gz 9S :fis cs'ggg Ev; 5, a s r g 5352 -:0: 559 a a)? g-:50 e" s) V 808": EOQC ,q1; o ic sa o: c 80 5a Q :1 .g' was: :a a b s g- ESEE 52 5 =aaisles 53 c .2 a. we". agEs seeps 'a se W 22? as; -fiai 5 2 a a woe as 5,355.. :aeae 35 5 28s: asses Eigs a s sass 52 2s 3555s 55552 as 525 see "5552a 35% 5 a as ga e =6 1 9 :11 Q at c. PG 0 1:. I 4

300 75 45 3 0 0 s 107 as 1.8 13 400 300 30 2 30 50 12 42 23 1. e 14 persed to the point of use. In such a frothing machine, Example 2 L a suractant essential A series of compositions were prepared the ingredients However, in ordinary d1spens1ng machmes, wherein the bemg 1n two portions as follows. foaming compos1t1ons are dispensed before foaming starts, the use of a surfactant is often desirable. In many recipes, W t A M t B it has been found that reduction of the amount of surwe factant to the point where the bubbles just burst as Aldo] t ime pf 13 Ldh F1 b Wfi ,d 5/

l I O ormy l y- 110 OIIC ac: 11051 I010 2C1 Polymenzatlon 15 Complete glves foams of the known dro-2H-pyran admixed with 2.7% solution in water. open cell structure, gig/2101'omorlofiupromethane l 0 l' y 170 urne t mventlon W111 '2 more fully lllustrated the 3,4-dihydro-2H-pyran-2methyl-(3, Polypropylene glycol of molecular lowlng examples, but it is to be understood that 1ts scope Y Q- 'Dl welsht 2025- 4 ate) adnuxed with pentachloro- 1s not l1m1ted to the spec1fic embodlments shown. Parts phemL e5 n i 1; 1 th Low molecular weight resinous p entag give are by gh u ess erwl condensate of epichlorohydrin indicated. I and 2:2-di-p-hydroxyphenyl The aldol residue-linked dlhydropyranyl compound em- Propane Dlphenylmethane dusoeyanate. ployed 1n the followlng examples can be prepared by Show oxyalkylene copolymer the slow addition of concentrated aqueous sodium hytype suliactantdroxide to a 77% v./v. solution of 2-formyl-3,4-dihydro- ZH-pyran in trichloromonofluoromethane. Although the Mixture B was added to Mixture A with vigorous stirexact structure of the product is not known it i believed ring and the mixture was then poured into a mould. The to be a trimer of 2-formyl-3,4-dihydro-ZH-pyran. In the proportions of the ingredients and characteristics of the examples this material is designated as the aldol trimer resulting foams are shown in Table II.

TABLE 11 ieg a, A a $5 "5 a I: is a g::-: '3 A .a r: 0 2" o" 5. 22 ai a assesses is as a? s a 5 3- 11 5 its -9 2 E as 2;; 2c 1's 2 .1 5 a "11:5 2. 5255? iaiggn ags: gs, a 5 e a .5 gat u s 5 fl e ee Go 5 as as o 5 'UE'E: Us? a e-;S Pinch-:5 gne 'ig'ssghggt a 9 Po 963-: 6:: a ass. e'meea'g -ga as $58 so 2 5 5 35, sa a a fia A :F gEllw ewi-u\ M5 05* o? 2*? :1 E, Egu 2": 552%,.75 ibis-E 293 g 53 22 3 E 8 5 23:31 E5 gsgs egg- 5 55 53 5 857535;: as 5 g @111; 5 g =5 ags 1 9 3 g;

1 g m g "Em-Ease 255152. 2252153 saw as Eu gas 2:: 2 a .5 551252 @5325 G r; r-r 4 (3 m at at ,2 at i=1 i=1 o 23.6 200 100 2. 20 15 2 1.5 20 10 20 2&8 E 5; 29.5 10 r 115 2.1 20 15 2 1.5 20 10 25 (20%) 2 125 2:1 20 15 2 1. 5 20 15 40 200 1m 1:1 20 15 2 1.5 20 15 30 175 125 1:1 20 20 2 1. 5 20 175 125 1:1 20 20 2 1.3 20 10 20 1 inch cubes of these foams withstood boiling for 3 weeks in water without noticeable change.

2 20 cc. of trichloromonotluoromethane added to Mixture A. 3 Instantaneous.

7 Example 3 The two following mixtures Were prepared:

Mixture A Mixture B Fluoboric acid/fluosilicic acid 45.5/2.7% in water, 1.2 cc. Polypropylene glycol of 2025 molecular weight, 20 grs.

Mixture B was added to Mixture A with vigorous stirring. After an induction period of 20 seconds a sticky, white, weak, even textured, resilient foam was formed with a rise time of 50 seconds. After curing in an oven at 60 C. for 2 minutes the skin became tack free. The foam shrank overnight.

When there were added to Mixture A 20 parts of diphenyl methane diisocyanate and an additional 20 parts of the low molecular weight resinous condensate of epichlorohydrin and 2:2-di-p-hydroxyphenyl propane the shrinkage and stickiness of the resulting foam was reduced. This foam in 1 inch cubes was maintained in boiling water for 1 week, during which time it retained ap proximately its original shape but shrank slightly. The pH of the aqueous solution fell to 6.

Example 4 The two following mixtures were prepared:

Mixture A Mixture B Boron trifluoride ether-ate in polypropylene glycol of molecular weight 2025 (1:5), 10 cc.

Mixture B was added to Mixture A with vigorous stirring. After an induction period of 15 seconds a foam was formed which rose for 50 seconds.

Example 5 The two following mixtures were prepared:

Mixture A Mixture B Boron trifluoride etherate in polypropylene glycol of MW 2025 (1:4), cc.

Polypropylene glycol ct MW 2025, 30 grams.

Aldol trimer of 2-iormyl-3,4-dihydro-2H-pyran admixed with trichloromonofluorornethane (80/20 by volume), 225 grams.

1:1 mixture of 3,4'dihydro-2H- pyran-2-methyl-(3,4-dihydro2H pyran-2-carboxylate) and chlorendic anhydride, 75 grams.

Low molecular weight resinous condensate of epichlorohydrin and 2 :2-di-p-hydroxyphenyl propane, 60 grams.

Mixture B was added to mixture A with vigorous stirring. After an induction 'period of seconds a foam with rise time of seconds was formed.

Example 6 The following stock solution was prepared:

Grams Aldol trimer of 2-formyl-3,4dihydro-2H-pyran admixed with trichloromonofluoromethane (/20 by volume) 2000 Trichloromonofluoromethane 1000 3,4 dihydro 2H-pyran-2-methyl-(3,4-dihydro-2H- pyran-Z-carboxylate) 400 Tetrachlorodiglycerylphthalate 400 The following two mixtures were prepared:

Mixture A Mixture B Boron tn'fluoride etherate polypropylene glycol (1:4), 8 cc.

Polypropylene glycol of molecular weight 2025, 30 g.

Stock solution above, 300 grams...

Mixture B was added to Mixture A with vigorous stirring. After an induction period of 35 seconds and rise time of 55 seconds a white, resilient, even textured foam with good skin was formed.

Exam pi e 7 The following two mixtures were prepared:

Mixture A Mixture 13 Stock solution (as in Example 6),

300 grams.

Low molecular weight resinous condensate 0t epichlorohydrin Fluoboric acid/fluosilicic acid, 45.5/

2.7% in water, 1.3 cc.

Polypropylene glycol of molecular weight 2025, 20 grams.

and 2:2-di-p-hydroxyphenyl propane, 80 grams. Siloxane oxyalkylene copolymer type silicone surfactant, 2 grams.

Mixture B was added to Mixture A with vigorous stirring. After an induction period of 20 seconds and a rise time of 25 seconds a white, resilient, hard foam which was not sticky was formed.

When 15 grams of diphenylmethane diisocyanate were added to Mixture A and an additional 0.3 cc. of the fluoboric acid/fiuosilicic acid catalyst were added to Mixture B a harder foam resulted. When 1 inch cube samples of the latter foam were maintained in boiling water for 1 week no change in structure or shape was observed.

Example 8 The following two mixtures were prepared:

Mixture A Mixture B Fluoboric acid/fluosilicic acid,

45.5/2.7% in water, 1 cc.

Polypropylene glycol of molecular weight 2025, 10 grams.

Aldol trimer of 2-iormyl-3,4

dihydro-2H-pyran admixed with trichloromonofiuoromethane (80/20 by volume), 246 grams.

Reaction product of ethylene glycol and 3,4-dihydro-2H pyran-2-methyl-(3,4-dihydro- 2H-pyran-2-carboxylate) (112.3 moles), 36 grains.

Siloxane oxyalkylene copolymer type silicone surfactant,

2 grams.

Mixture A of 40 parts of the low molecular weight resinous condensate of epichlorohydrin and 2:2-di-p-hydroxyphenyl propane, and 20 grams of diphenylmethane diisocyanate; and the addition to Mixture B of 10 grams of 10 Mixture B was added to Mixture A with vigorous stirring. After an induction period of 35 seconds a foam was formed with a rise time of 40 seconds.

A series of 8 foams of this formulation was prepared.

polypropylene glycol of molecular Weight 20 a re- 5 In general these foams were white, even textured but placement of the fiuoboric acid/fiuosilicic acid catalyst k d f i b1 y 1 F- of boron trifilloride eihefate When the composition was modified by the addition to lure Wlth P }'P PY Y 0f mOleCular wfilghi 2025 Mixture A of 20 gram and 30 gram portions of a 1:1 or the characteristics of the resuiting foams were not altered 2;1 b d f 3 4 ih d [pp .2. m. 3 4 13; Pp f' yi Omission of dipherp'lmflhane 1O dro-ZH-pyran-Z-car'boxylate) and 2:2 di-p-hydroxyphenyl cyanate ingredient did not result in a noticeable change in propane the foams produced Possessed Substantially the he foa same properties.

Example 9 Ex m e 10 A stock solution was prepared containing: a

Parts Aldol trimer of 2-formyl-3,4-dihydro-2H-pyran adi f fi gii g ff igfg 3? adding i mixed with trichloromonofluorornetl'iane (80/ Th a e e lgorous lmnb' e composition and resulting foams are shown in Table by volume) 100 IH 3,4 dihydro 2Hpyran-2-methyl-(3,4-dihydro-2H- 20 pyran 2 carboxylate) admixed with 2:2 di-hydroxyphenyl propane (4:1) 20 TABLE III Mixture A Mixture B e a-EH a a 2a 5 2E2 2 @i =5 5 5 a e "a: 2 ED 5 e .-s '7 :1 2 SE, o g e a E3}; s2 a a g H a r 2:: K e g g a o gas 2 s 5 e e e515 g 'g A E? r Remarks ias a a ae a s 5% a :q: ne; BELLE," =1 "e 0 g 8, 5E 32?0 a) S 5 g 1; "E252 E V 5 92 3 :f o 5 ew? 2*? 53 g, 2 a an QA F 3: 5 =15 ewe a ee .=O- go Ease Zea Essa a se -22 :22 e .2 :0 A i 2 e E 5 a:

150 150 20 O 2 7 2 75 35 White, brittle skin, scorched. 150 150 20 5 2 7 2 90 35 Soft, sticky skin hardened in 3 minutes. 150 150 20 5 1. 5 7 2 25 10 Hard skin, no shrinkage.

Example 11 t M' B Mm me A mum The followin stock solution was pre ared:

Fluoboric acid/fiuosilicic acid,

45.5/2.7% solution in water, 1.2 cc.

Polypropylene glycol of molecular weight 2025, 20 grams.

Aldol trimer of 2-formyl-3,4-dihydro-2H-pyran admixed With trichloromonofluoromethane (20/80 by volume) grams 500 3,4 dihydro 2H pyran 2 methyl (3,4 dihydro-2H-pyran-2-carboxylate) grams 100 Trichloromonofluoroinethane cc 300 and 10% p-toluene-sulphonic acid solution in ethylene TABLE IV 1 l lycol with portions containing boron trifluoride etherate catalyst and a polyol. The composition proportions and character of the foams are shown in Table IV.

Foam withstood one week exposure in boiling water without brmkdown.

Mixture B was added to Mixture A with vigorous stirring. The characteristics of the foams produced are shown in Table VI.

In general these foams lack strength and shrink on standing. They also tend to be scorched. 5

TABLE VI Variable Ingredients Low molecular Fluoboric acid] weight resinous Diphenylmethane fiuosilicic acid Polypropylene glycondensate of Styrene (grams) diisocyanate 45.5/2.7% solution col of molecular Introduction Rise Time epichlorohydrin (grams) in water (cc.) weight 2025 Period (sec.) (sec.) and 2:2-di-p- (grams) hydroxy-phenyl propane (grams) 20 1. 15 2O 1. 4 5 10 20 1. 4 20 12 15 1. 4 30 30 20 2O 1. 4 40 35 30 20 1. 4 50 55 30 20 1. 4 60 75 30 30 1. 4 50 55 1. 4 40 2O 4O 1. 4 35 40 1.4 40 35 25 40 1. 4 40 45 25 10 1. 2 40 30 10 1. 5 40 3O 2O 1. 5 20 Heated mould.

Example 14 Example 15 A series of foams was made from ingredients prepared ed' t re- A series of foams was made from mgr mm s p as the following two mixtures:

pared in the following two mixtures:

45 Mixture A Mixture B Mxture A Mixture B Aldol trimer of 2-forrn l-3 4-di- Fluoboric acid fiuosilicic acid Ala-01 fi i 2 formyl 1 Fluobon-c 301d, 31051-11010 hydro-2H-pyran adriixed with 45.5/2.7% solr ltion in water or d1hydro--H pyran admixed 45.5/2.1% solution in water. 1 with trichlommonofiuomme trich oromonofluoromethane boron tnfluonde etherate 1n mane (30/20 by vo1ume) 50 (/20 by volume), grams. polypropylene glycol (1.4), as in Trichloromonofiuorornethane. 441m d OH h 1 Tble VHL Low molecular resinous com 3, roan ityrann'et y Poly propylgne glycol of molecular densate of epichlorohydrin and my f 1f? Y 20-51 as Table VIII- 2.2 di p hydroxyphenyl pmpane onylate) a med with l2-d1-p- Trlchloromonofluoiomethane, as Polypropylene glycol of m l l hydroxyphenyl propane in proin Table VIII.

weight 2025 portion 4:1, 150 grams. styrene Low molecular weight resinous 50 condensate of epichlorohydrin and 2 2-d.i-p hydroxyphenyl propane, as in Talole VIII. The proportions of the ingredlents employed are shown Dlphenylmethane dllsocyanate, I as in Table VIII. in Table VII. The foams were prepared by adding Mixture gimme oxyalkylene copolymer B to Mixture A with vigorous stirring. The characteristype 511100118 Surfactant, 2 a ucs of the foams are shown in Table VII. 60

TABLE VII Low molecular Aldol trimcr of weight resinous Fluoborlc acid/ 2-forrnyl-3, 4-dihydro condensate oi Polypropylene Styrene Trichloromonofluosilicic acid Induction Rise time QH-pyran/trich oroepichlorohydnn glycol of molecular (grams) fluoromethane 45.5/2.7% solution time (see) (see) monofiuoromethaue and 2:2-p-diweight 2025 (grams) (cc.) in water (00.)

(grams) hydroxyphenyl propane (grams) 50 4 10 10 25 0.6 60 10 30 10 30 25 O. 7 300 75 30 I 10 30 25 1. 0 135 45 40 1O 25 25 1. O 270 60 40 1U 20 25 1. 2 270 30 30 10 30 25 1. 2 30 Mixture B was added to stirring. The resulting foams varying ingredients are shown Mixture A with vigorous and the proportions of the in Table VIII.

TABLE VIII Low molecular Fluoboric acid] weight resinous con- Polypropylene Triehlorofiuosilicic acid Boron trifluoride densate of e ichlo- Diphenylmethane glycol of molecular monofluoro- 45.5l2.7% soluetherate in poly- Induction time Rise time rohydrin an 2:2-didiisocyanate weight 2025 methane tion in water propylene glycol (see.)

p-hydroxyphenyl- (grams) (grams) (ec.) (0a.) (1:4) (cc.) propane (grams) 60 65 25 v 50 10 45 25 40 10 35 25 40 10 l5 40 10 30 40 10 75 40 10 6O 25 60 10 6O 2O 40 10 120 40 Example 16 Example 17 A series of foams was made from ingredients prepared as the following two mixtures:

A series of foams was made from ingredients prepared as the following two mixtures:

Mixture A Mixture B 25 Alaicl ggmer of 2-ggxylt-l3Adlilhg7r-i The following ingredient was prero- -pyran a e wit pare separate y: v V chloro-monofluoromethane (80/20 p-tert. butylphenol-tonnalde- Mnture A Mnture B a fiuz ti r zi'i 2 1:11 1 P liydle i 28 i i' r y o- -pyran- -me y o ypropy ene g yco 0 mo- (3,4-dihydro-ZH-pyran-Marboxleeular weight 2025, 5.6 parts. 30 4 of n Boron tnfiuonde ylate) admixed with 2:2di-p- Trichloromonofluoro-methane, admlxed POIYPYOPYMQ glycol of molecular hydroxyphenyl propane in 40 parts with tnehloro-monofluoroweight 2025. portions of Mixture B was then prepared com methane (g0/20 by volume). Trichlorornonofluoro-methane.

Low molecular Weight resinous taining- E g g d; condensate of epiehlorohydnn Ingredient above, 37 parts. I b y i 7 and 2:2-di-p-hydroxypbeny1pro- Polypropylene glycol of moq fi g a f 1 pane. leeularweight 2025, 30 parts. -g gs; 3 5 23 Propane glgtilrylmethane dusoeyanate. Bgrgstnfluonde etherate, 25 Low molecular Weight resinous condensate of epichlorohydrin and 2:2-di-p-hydroxyphenyl Mixture B was added to Mixture A with vigorous stirg gfigh melamine formalde. rlng. The compositions and resultmg foams are shown m 40 y resm u af VDM)- Table 1X.

TABLE IX A a o i r. F; E o 6 m d p I: 4533 1,: g 2% gee a 5. g5. 8 :5 a a. 3:: 2 6 3 a) :1 g; 5%0: I .Ag. ao E, A .3 an; g 0 A W e 5 s? 2% 5 is a d s e 2;, a 2 5?.2 EL; Eggni e: 3 3 $53, a 0V :3 5 1S .E'SZ Q' QA $w':"-? .55 in 5 2 53 i "a:' 691 35 r l V 2* 2st M 0 5 a SQZ QSNE ofl c :0 Q 2 Q 80 0; 1'5 M -EQGQE isb es fi wg s z :3 I30 a -Q E U 9 o ;q 'UE'OQIEL "r 2 a 0-: g 0 28015 39 seesa issue as as as. :56 g :2 1 :6 A Q :5 2 m m E- H m 150 150 20 40 10 30 20 150 150 20 40 10 V 40 15 150 150 20 '40 10 30 150 150 10 2 4O 10 205 30 150 150 10 2. 3 4O 10 65 20 150 150 10 2 4 4O 10 45 20 150 150 10 2. 4 4O 15 30 15 150 150 2. 4 40 15 35 10 150 150 2. 4 15 50 15 250 125 10 2. 4 50 20 25 250 125 10 2. 6 7O 25 45 15 250 125 10 2. 8 25 r 250 10 2. 8 70 25 17 Mixture B was added to Mixture A with vigorous stirring. The compositions and resulting foams are shown in Table X.

TABLE X A Q Q I 9. E w c o F. I A & 88; 5 5 e 5 3 -2 8i. 3 d ee '02: filgp u 0911.6 Em w" 3 ue- 5 ox s'en afl- .2 o .-.w d v er -E2 "a me: EE--72 s a 73,. 3 23 to 5 e g 2: 55 Egigfi; gez- 52 e3 55? e5 2 3 eEgA Elia er ie: eiersl fish e Em 2 e 3235 l -raw sh-1 9: "5139120 EE '2 2E: on g 521E zgop g gg-amzlg SE05 =2 Eg as a: 2 5:5 c: s fig i s b "501 a E4 0 5 iae sees-ea gasses eeee gs gee e2 5 a e ga e 1 :6 1-1 2 m m E 1: :4 Q r=l 1 Polypropylene glycol of molecular weight 425. 4 Overall. gontained rise in preheated mould. 5 Closed cell content 84.3%.

are.

Example 19 Example 18 A series of foams was made from ingredients prepared 20 as the following two mixtures:

Mixture A Mixture B Boron trifluoride dillydrate.

Polypropylene glycol of molecular weight 2025.

Tricliloromonofluoromethane.

Mixture B was added to Mixture A with vigorous stirring. The compositions and resulting foams are described 40 in Table XI.

A series of foams was made from ingredients prepared as the following two mixtures:

Mixture A Mixture B Polypropylene glycol of molecular weight 2025 or 1025, as in Table Fluoboric acid/fluosilicic acid 45.5]

2.7% solution in water, as in Table XII.

Trichloromonotluoromethone, as in Table XII.

Mixture B was added to Mixture A with vigorous stir- TABLE XI 9 x o 0 4 5.4.6. we: s .1 e 2 as :2 gas a. 52 g; gg a e g g Q ,,u g 0. g 0 q H a o g 2 3129? .2 r3 Qw e 3 E E5 s sees 25 e e w e; a A, :1 egg .1 5 .4. e =15 0 ea 5 s 2 9 l fl 5:36;; 5 A g e E L, z e. 2 s, AE e 5H a u A m aw-J g: QS H 03S 2 g c 0 2 s 3.5g 2 3 552 e *5: 5 g 5-5 s E :3 5.2.2 1612? 85::1. '2 E E5 33 a; g g 9 62 B as 35 #1? g e 22' 3; 3 .2 a h r: 2 51's Ewg'E at; 5., A 2,. p a :1 2:22 efkfig 1522 ego a; as e5 5.; 3 o e 356 4 5254 5821-19 8e .9: E S 3. "g 2 a .6 A 2 Q .4 a. at a a m :3

00 200 10 2 a. 2 60 40 145 60 200 200 10 1. 5 60 40 405 so 200 200 10 1. 5 e0 30 390 so 200 200 10 1. 5 40 30 150 200 200 10 1.5 30 45 45 200 200 10 1. 4 so 30 150 so 200 200 10 1. 4 so so so 50 200 200 20 1. 6 so 120 60 400 400 20 3. 2 120 55 45 *Preheated mould, contained rise.

Rise time (sec.)

Non-burning. Burning. Non'burning.

Do. Self-extinguishing.

D Do

Do. Do.

fiuoromethane.

TABLE XII Polypropylene Fluoboric acid/ glycol of molecufluosilicic acid Trichlorolar weight 1025 45.5/2.7% solution monofluoro- (grams) in water (00.) methane (cc.)

Mixture B 3 2. 28 Non-burning.

Polypropylene glycol, molecular weights 425,

Boron tn'fluoride etherate or boron trifluoride dihydrate or fluoboric .acid/tluosilicic acid 45.5/2.7%

solution in water.

The boron triiluoride etherate was dissolved in the polypropylene glycol.

Tn'chloromono Ga 875 A963 mafia Example 21 drin -2-methyl-(3,

-2-carboxyl1 2:2-di-pht resinous 32v Bea 523 5 M m m m m m m w 1 1 Mixture A fiuoromethane -pyra l propane in the hydroxyphenyl lkylene copolymer -pyran admixed Wit admixed wit A68 .623 5 :5 madame E m m m m m m m m m m 20525533 225055 1 i 5888 LLLL A series of foarnswas made from ingredlents prepared ldol trimer of 2-formyl-3,4-dihydro-2H trichloromono (80/20 by volume). 3,4-dihydro-ZH-pyran 4-dihydro-2H late) hydroxypheny proportions of 4:1. Low molecular weig condensate of epichlorohy and 2:2-di-ppropane. Siloxane oxya type silicone surfactant.

Mixture B was added to Mixture A with vigorous stirring. The compositions employed and the resulting as the following two mixtures:

foams are described in Table XIV.

TABLE XIII Mixture B Low molecular weight resinous condensate of epieliloroliydrin and 2:2-di-p-hyclroxyphenyl propane (g a ring. resul weight 1025. Trichloromonofluoromethane.

Fluoboric acid/fluosilieic acid,

45.5/2.7% solution in water. Tris (2,

Phosphate.

3223 acaccnsbau nw 0 5. 53853% 2 3 31.23 28 5 Bog Example 20 g to A.S.T.M. D-1692-59T. The

n-2-carf foams was made from ingredients prepared Mixture A pyran-Qanethyl- H-pyra d with 2:2-di-pp-hydroxyphenyl alkylene copolymer ing characteristics of the resulting foams L'nethane diisocyanate.

series 0 as the following two mixtures pyran admixed with tn chloro-monofluorornethane (80/20 by volume).

pane.

(8,4-dihydro-Z portions of 4:1.

Low molecular weight resinous condensate of epielilorohydrin and 2:2-dipro Dipheny Mixture B was added to Mixture A with vigorous 45 stirring. The burn Aldcl trimer of 2-formyl-3A'dihydro- Polypropylene glycol of molecular boxylate) admixe hydroryplicnyl propane in pro Siloxane oxy type surfactant.

were tested accordin compositions and characteristics of the foam-s are described in Table XIII.

1 The iluoboi'ic acid/fluosilicic acid catalyst was replaced by boron ti'ifluoridc elheralc in polypropylene 3 Instant. lrcheated mould.

2* gs 23.826 E E Qt 3 5 A208 E QQ SH 75 232:; KEQS A 3 26 8 8 33 mm Mixture B Polypropylene glycol of molecular weight 425.

Boron trifluoride etherate, dissolved in polypropylene glycol ingredient.

Trichloromonofiuoromethane.

Example 23 mg 1W0 mixtures Mixture A pyran-Zanethyl- 1.0 part.

phenyl propane,

25 part.

A series of foams was made from ingredients prepared dihydro-ZH-pyran admixed with trichloromonofiuoromethane (80/20 by volume), 1.25 parts.

,-dihydrcyZH-pyran carboxylate) i-p hydroxy 0.25 part.

condensate of epichlorohydrin and 2 2 di-p-hydroxyphenyl propane, 0.0

type silicone surfactant, 0.016 part.

Additional silicon surfactants (as indicated in Table added to Mixture A with vigorous stirring. The compoas the follow' Aldol trlmer oi 2-formyl-3,4

3,4-dihydro-2H- Low molecular weight resinous Siloxane oxyalkylene copolymer XVI) were added to Mixture A. Mixture B was then @553 mmom EH95 2:523: 0 623m 3.038530% tions employed and the resulting foams are described Table XVI.

TABLE XIV 9 $3 mmi, E1623: 392m ESEQEQE TABLE XV SE53 3: 299: E33 5 0 Swim esghnoaficm TABLE XVI @559 mm Ewe? E33 5 222w osogaoabom Mixture B Polypropylene glycol, molecular weights 150, 425, 1025, 2025.

Triohloromono-fiuoromethane.

Boron trifluoride etherate, dissolved in the polypropylene glycol ingredient.

Example 22 tWO mixtures:

yl- 3, i-dihy- Additional sili- Wm .la 55 mflu 3333 e k. Dr wm o 00 .1 mmu 88 e N. LLLL P b a a m o 0500 6 3333 aw .1 R H 0 w 5 5 m m 7m? m I c mmo mm 1 8 5-35 hfln W222 C03 .1 mm Tmm 81d 2 w 0 0 m m m6 1r Wo l v. e m a ma a w E3 fl w 2222 m8 m r t w t 22 c .m r u 5 av H 0 c Preheated mould.

A series of foams was made from ingredients prepared Mixture A (/20 by volume).

, 4-dihydre-2H-pyran-2-car- Mixture B was added to Mixture A with vigorous stirring. The compositions employed and the resulting foams are described in Table XV.

as the following clro-ZEI-pyran admixed with tl'ichlormmonofluoromethune hyrlroxyphenyl propane in the proportions 4:1.

condensate 0t epichlorohydrin and 2:2di-p-hydroxyphenyl propane.

type silicone surfactant.

Aldol trimer of 2-forrn 3, 4dihydro-2H-pyran2-methylboxylate) admixed with 2:2-di-p- Low molecular weight resinous Siloxene oxyalkylene copolymer Mixture A (grams) The moulds were preheated.

Mixture B Boron trifluorlde etherate or 11 Boron trifiuoride dihydrate, the

boron trifluoride etherate being dissolved in the polypropylene glycol ingredient.

Trichloromonofluorornethane.

Polypropylene glycol of molecular Weight 425.

10% p toluenesulphonie acid in ethylene glycol solution.

Example 25 n-2-carbox- -pyran admixed wit fiuoromethane pyran-Z-methyl H-pyra d with 2:2-di-p- Mixture A A series of foams was made from ingredients prepared as the following two mixtures dihydro-2H triehloromono (80/20 by volume).

(3,4-dihydro-2 ylate) admixe hydroxyphenyl propane in pro- I portions of 4:1. 0 Silicone surfactant Dow 201.

Mixture B was added to Mixture A with vigorous stirring. The compositions employed and the resulting foams are described in Table XVIII.

Aldol trimer of 2-formyl-3,4 1 0 TABLE XVII Mixture B 'd/fluosilicic acid Polypropylene glycol of molecular weight 425. Fluoboric aci 45.5/2.7% solution in water or Boront-rifiuoride etherate dissolved in the polypropylene glycol ingredient. Trichloromonofluoromethane.

Example 24 A series of foams was made from ingredients prepared as the following two mixtures:

Mixture A formyl-3,4-dihydro-2H-pyran admixed with trichlorornonofluoromethane (80/20 by volume). v 3, i dihydro-2H-pyran-2-metl1yl- (3,4-dihydro-2H-pyran-2-earboxylate) admixed with 2:2-di-phydroxyphenyl propane in proportions 4:1. Low molecular weight resinous condensate of epichlorohydrin and 2:2-di-p-hydroxyphenyl propane Silicone surfactant Dow 199 or Dow 201. Diphenylrnethane diisocyanate.

Mixture B was added to Mixture A with vigorous stirring. The composiitons employed and the resulting foams are described in Table XVII.

Aldol trimer of 2- ileaterl moulds.

Example 26 Example 27 A series of foams was made from ingredients prepared as the following two mixtures:

Mixture A Mixture A Mixture B Mixture B (proportions variable) Boron tritluoride etherate, dis- Aldol trimcr of 2-formyl3,4-disolved in the polypropylene hydro-2Hpyran admixed with tric'nloromonofluoromethone glycol ingredient. (80/20 by volume). Polypropylene glycol of molec- 3,4-dihydro-2H-pyran-2-methylular weight 425.

(3,4-dihydro-2H-pyran2-car- Trichloromonofiuoromethane. boxylate) admixed with 2:2-dip-hydroxyphenyl propane in proportions of 4:1. Diphenylmethane diisocyanate.

Aldol trimer of 2 forniyl-3,4

dinydro-2H pyran admixed with trichloromonoflnoromethane (80/20 by volume), 50 parts.

10 3,4-dihydro-2H-pyran-2-methyl- (3,4-dihydro-2H-pyran-2- carboxylate) admixed with 2:2-di-p-hydroxyphenyl propane in proportions of 4:1, 50 parts.

Diphenylmcthane diisocyanate,

Polypropylene glycol of molecular weight 425.

Trichloromonofiuoromethane.

Castor oil.

Boron trifluoride etherate, dissolve in the polypropylene glycol and castor oil ingredients.

Dibutyltin dilaurate.

Silicone surfactant Dow 201. 1 3 parts.

TABLE XIX l I Aldol trimer of 2- 3,4dihydro-2H-! lormyl-3,4-dipyran-2 i Diphenyl Silicone Polypro- Trichloro- Boron hydro-2H-pyran/ methyl-(34 methane surfactant pylene monofiuorotrifiuoride Induction Rise time Density Density trichloromonodihydro-ZH- diisocya- Dow 201 glycol momethane etherate time (see) (see) (core) (overall) tlnoromethane pyranZ-carbnate (grams) lecular (cc.) (cc.) (lb./cu. it.) .(lb./cu. it.) (80/20 by volume) oxylate)/2:2-di- (grams) Weight 425 (grams) p-hydroxy- I (grams) |phenyl propane, I (4:1) (grams) I 175 175 13 1 53 80 2. 4 70 60 2. 32 175 175 13 l 53 80 2. 6 55 45 *175 175 15 1 60 80 3. 30 35 2G0 200 15 1 60 O 2. 8 30 35 2. 3

THE LAST FOAM ABOVE HAD THE ADDITIONAL CHARACTERISTICS DIMENSIONAL STABILITY Force required for 10% compression Parallel to direction of rise 11.6 lb./sq. in. Perpendicular direction of rise 8.4 lbJsq. in. Temperatu e 24 ou 7 y 28 days, Force required for compression. Percent Percent Percent Parallel to direction of rise 11.5 lb./sq. in. Perpendicular direction of rise 8.75 lb./sq. in. 3D 6 K factor 0.146. C. l9. 5 -13.2 +3.35 Heated moulds. Room +0. 7 +1. 6 33 Mixture B was added to Mixture A with vigorous stir- 40 ring. The compositions employed and the resulting foams are described in Table XIX.

To mixture A was added a silicone surfactant and then Mixture B with vigorous stirring. The compositions and resulting foams are described in Table XX.

TABLE XX Poly- Silicone Silicone propylene Trichloro- Boron tri- Dibut-yltin Castor Induction Rise Density Density Mixture A surfactant surfactant glycol of monofluoride dilaurate oil time time (core) (overall) (grams) Dow 201 11-520 molecular fiuoroet-nerate (cc.) (grams) (11 it (1b,/ 3,)

(grams) (grams) weight 425 methane (cc.)

(grams) (cc.)

1 415 2 6O 80 3 75 60 415 1 60 20 2. 8 135 60 415 1 60 20 3. O 35 415 1 00 20 2. 9 35 415 1 60 50 3. 2 20 40 415 1 60 50 4. 0 60 415 1 60 4. 3 20 30 415 1 6O 5O 4. 3 35 30 415 1 50 2. 8 Instant 20 415 1 50 2. 7 5 20 415 1 50 50 2. 6 10 20 Norn.The first foam in Table XXI was maintained in boiling water. After 2 days shrinkage was observed. After 7 days the foam was partly water logged. After 10 days discoloration and shrinkage had taken place.

Example 28 A series of foams was made from ingredients prepared as the following two mixtures:

Mixture A Mixture B (proportions variable) Aldol trimer of 2 forInyl-3,4

dihydro-2H-pyran admixed with trichloromonotluorornethane (80/20 by volume), 50 parts.

3,4-dihydro-2H-pyran-2-methyl- (3,4-dihydro-2H-pyran-2-carboxylate) admixed with 2:2-di-phydroxyphenyl propane in proportions of 4:1, 50 parts.

Diphenylmethane diisocyanate, 3

parts.

Boron trifluoride etherate dissolved in the castor oil and polypropylene glycol ingredients.

Castor oil.

Polypropylene glycol of molecular weight 425.

Methylated melamine formaldehyde resin (V ulcafor VDM).

Trichloromonofiuoromethane.

Density (overall) (lo/cu. it.)

gar alcohol Density (core) (lb. /cu. ft.)

Q; 3 9: 3 8 Si n" Mixture B PEP-450).Castor 380 Polyether alcohol of Tacktree time (sec.)

molecular weight 440.

molecular weight 700.

hexahydroxy su of molecular weight 700.

pentaerythritol of molecular weight 400.

3:5 2:: oecowvwm Polyol (LK-380, LET-240,

Hexol-490 oil. 'lrichloromonofiuoromethane. Boron trifluon'de etherate, dissolved in polyol ingredient:

LET-240 Polyether alcohol of Hexol-49O Polypropoxylated PeP-45O Polypropoxylated Rise time (see) Example 30 38 was E52 5 Induc (see) Wethylated melamine resin (Vuloafor V DM) (cc.)

Mixture A 7 A series of foams was made from ingredients prepared as the following two mixtures:

dihydro-ZH-pyran admixed with trichloroniono-fiuoromethane (SO/201w volume). V 3, 4-dihydro-2H-pyra (3, 4-dihydro-2 boxylate) admire p-hydroxyphenyl propane in proportions of 4:1. Diphenylmethane diisocyanate. Silicone surfactant Dow 201.

Mixture B was added to Mixture A with vigorous stir- Aldol trimer of 2iorrnyl-3, 4-

in Table XXIII.

TABLE XXI Boron trifluoride formaldehyde tiontimc etlzlcrejte cc.

ring. The compositions and resulting foams are described TABLE XXII Trichloroono-fluoromethane 2 Heated mould.

Polypropyh one glycol m of molecular weight 425 (grams) Mixture B Polyol (glycerol, LK, 380, LHT

112, LG 56, LA 700, LG168).*

Castor oil.- Trichloromonofluorornethane. Boron trifluoride etherate dissolved in the polyol ingredient.

Dibutyltin dilaurate.

molecular weight 440. L

ar weight 1 1t 2800. LA 700P'ol v- 393. LG 16SPo1yether 352$ 5m BQ .6 385m Castor oil (g s) Example 29 Silicone surfactant Dow 201 (grams) two mixtures:

Mixture A -3, 4 mixed with -2-methylpyran-2-carhane dilsocyanate. Dow 20l alcohol of molecul f molecular weigl hol of molecular weight To Mixture A was added a silicone surfactant and then Mixture B with vigorous stirring. The compositions and resulting foams are described in Table XXI.

Mixture A dihydro-2H-pyran ad trichloromonofiuoromethane (/20 by volume). %dihydr0-2Hpyran boxylat Mixture B was added to Mixture A with vigorous as the following Aldol triruer of 240m Diphenylmet Silicone surfactant 112Polyether Polyether alcohol 0 ether alco alcohol of molecular weight 1000.

stirring. The compositions and resulting foams are described I 34 inch cube immersed in boiling water under reflux for 1 week showed change in shape but a loss of 13.4% in weight occurred. The pH of th no change in shape but lost 16.6% in weight. The resulting pll of the water solution at. termination of test was 6.1. solution was 4.5. 3 Alter immersion in boiling water under reflux for 1 week there was no 2 After immersion in boiling water under reflux for 1 week there was no change in shape or structure.

214 214 13 1 30 30 20 3. 5 Instant 30 220 220 22 1. 5 60(LHI-240) 10 3. 0 00 220 220 22 1. 5 30(Hex0l490) 20 20 3. 2 30 35 Example 31 Example 32 A series of foams was made from ingredients prepared as the following two mixtures:

Mixture A Mixture B Castor Oil.

Polyol (L 6-56, LIZ-380).

Trichloromonofluoroniethane.

Boron trifiuon'de etherate, dissolved in polyol ingredient.

Aldol tn'mer of 2-t'ormyl-3,4-

dihydro-2H-pyran admixed with trichloromonofiuoromethane (/20 by volume).

3,4-dihydro-2H-pyran-2-methyl- (3,4-dihydro-2H-pyran-2- carboxylate) admixed with tetraehlorodiglyceryl phthalale.

Diphenylmethane diisocyanate.

Silicone surfactant (Dow 201 or Union Carbide L-53l).

*LCr56-Polyether alcohol of molecular weight 2800. LK- 3S0-Polyether alcohol or molecular Weight 45-10.

Mixture B was added to Mixture A with vigorous stirring. The compositions and resulting foams are described in Table XXIV.

A series of foams was made from ingredients prepared as the following two mixtures:

Mixture A Mixture B Castor oil.

Polyol (LG-168, PeP-450).*

'Irichlorornonofiuoromethane.

Boron trifluoride etherate, dissolved in the polyol ingredient.

L Gl68Polyether alcohol of molecular weight 1000. PeP-450-Polypropoxylated pentaerythritol of molecular weight 400.

TABLE XXIV N v Q 9 A 25 2152 5 3' 3 5 25 5 5 5 2 o 5 e1 5 5 -s=e 2225 E: *5 5 E an A 5 3 v A fle e 52, e e 2 =2 '5 E 0 2A 5A 01 :8 mgwn EH T 3 21V 4: 33 E Q; Er' dga Y es- ;3 5A So E0 g g Q :4 3* 3H FM-cr w 'U'--= 4 4 H Q ge ce 2 -s g we "9 v e w $=a -=s%8s 2 =5 a e '5 .e :3 :23 ee B ware 5- -5 0 e5 55 4 =1 5 5 5 e Ewen-WI, E N-qbfiv at! Ev 8 4: gel '3 g N at, at,

:5 KIJ 9-4 H E1 200 /40 1 (Dow 201) 70 2. 5 30 10 15 200 /40 1 70 2. 2 30 10 20 200 100/40 1 70 2. 0 30 10 30 200 100/40 1 70 1. 8 30 20 40 200 leg/40 1 00 2. 0 go 10 30 00 15 0 1 00 1.8 0 15 30 200 133/07 2 (L-53I) 00 2. 2 30 15 2 2 00 g 20 4 20 15 25 -05 5 0 1 205 00/45 2 00 2. 0 2 i 205 108/27 2 00 2. 4 20 10 30 205 108/27 2 (Dow 201) 00 2. 0 50 10 20 205 108/27 2 00 2. 4 30 10 30 200 100/40 1 2. 2 20 210 so 200 100/40 1 2. 4 20 50 40 200 100/40 1 30 2. 2 20 45 50 200 100/40 1 30 2. 2 20 55 45 200 100/ 40 1 30 2. 3 30 30 40 45 220 /44 1 30 2. 4 30 30 (LII-380) 30 35 220 170/44 1 30 2. 7 20 30 35 45 220 170/44 30 2. 9 30 30 30 35 22 170/44 1 30 3. 0 30 30 20 35 220 170/44 1 2. 5 30 30 30 35 1 This composition contained in Mixture A an additional 25 hydroxyphenyl propane.

grams of low molecular weight resinous condensate of epichlorohydrin and 2:2-di-p- After immersion for 2 days in boiling water under reflux a specimen of the foam showed no changes in structure.

Mixture B was added to Mixture A with vigorous stirring. The compositions and resulting foams are described in Table XXV.

TABLE XXV cl: o e-a $1 Q I A A I A ,U q) A ..L t. ,1. A n i .n A A ivfi g E1342??? .4.5 a as g E a 6 0 54.94: ggsw; u 53v n Q n 3 g fl to h 13:11,; :55 We: E) H g imagin w E0; 01,; 3.2V 6 2? 5 =1 0 g Q EMMOOA ama 51 :6 :2 a =8 6 I 12 a -E5Q fig ad w t: and 6:: =2 58 1 0 so a 0' -*--.-:E 'U 2 E 2; e g, g, pug 3; a fig 2325:5351 t w c i 5am EKSV 2v 56 g, '3 Ev v 1 e 0; 1 Q m o m a 4 H a: a

diglyceryl phthala-te LG-168 220 176 44 20 1 3. 0 2o 50 150 45 220 176 44 20 1 *3. 0 30 50 60 150 Diallyl phthalate PeP-450 220 220 20 22 2 30 3. 2 15 so 150 90 220 220 10 22 2 3. 4 30 60 60 Dimethyl phthalate 220 220 30 22 2 30 3. 4 20 30 115 75 220 220 60 22 1 30 3. 6 20 30 115 65 Epon 828 220 220 25 22 2 3. 2 15 30 190 90 60 220 220 10 22 2 30 3. 4 15 30 90 60 30 Eponite 100 220 220 10 22 2 30 3. 4 20 30 120 60 220 220 30 22 2 30 3. 6 20 30 60 110 30 1 cc. of dibutyltin dilaurate added to this composition.

Example 33 Example 34 1 f 35 The fo.low1ng stock solution was prepared. The follow mg Stock sohmon was prepared:

Parts Parts Aldol trimer of 2-formyl-3,4-dihydro-2H-pyran admixed with trichloromonofluoromethane (80/20 by volume) 3,4 dihydro 2H pyran 2 methyl (3,4 dihydro- 2H pyran 2 carboxylate) admixed with 2:2 dip-hydroxyphenyl propane (80/20 by weight) Diphenylmethane diisocyanate 3 all density of 2.32 lbs/cu. ft. and measurements of the 7 core indicated densities of 1.65 and 1.67 lbs/cu. ft. The closed cell content of the foam was 82.2%. The force required for 10% compression of the foam was 17.8 lbs/sq. in. parallel to the direction of rise and 8.7 lbs/sq. in. perpendicular to the direction of rise. The force required for 20% compression of the foam was 17.9 lbs./ sq. in. parallel to the direction of rise and 9.7 lbs/sq. in. perpendicular to the direction of rise. The percentage change in dimensions of the foam under different conditions of temperature and relative humidity are shown in Table XXVI.

Aldol trimer of 2-formyl-3.4 dihydro-2l-l-pyran admixed with trichloromonofluoromethane (80/20 by volume) 50 3,4 dihydro 2H pyran 2 methyl (3,4 dihydro- 2H pyran 2 carboxylate) admixed with 2:2 di

p-hydroxyphenyl propane (80/20 .by weight) To 415 grams of the stock solution were added 1 gram of silicone surfactant Dow 201, 30 cc. of trichloromonofluoromethane and 2.4 cc. of borontrifluoride etherate dis solved in 60 grams of castor oil. The mixture was stirred vigorously and poured into a mould. After an induction period of 10 seconds the foam rose for 15 seconds. The

foam had an overall density of 2.28 lbs/cu. ft. and

TABLE XXVI TABLE XXVII Percent Change in Dimension Percent Change in Dimension of Foam After- Foam After- Condition Condition 24 hours 7 days 28 days 24 hours 7 days 28 days 23201, 50% RH 0 0 +1. 4 -3 -1.7 +0.1 100 C +3. 4 +15 +26. 5 +2. 6 +9. 4 +21. 2 +16 +15 25 1 3 7 33 Example 35 The following two mixtures were prepared:

34 Example 37 The following two mixtures were prepared:

Mixture A Mixture B Mixture A Mixture B Aldol trimer of 2-formyl-3Adi- Trichloromonofiuorornethane, Aldol trimer of 2-f0rn1yl-3A-di: Trichloromonofiuoromethane,

hydro-2H-pyran admixed with 30 cc. hydro-2H-pyran admixed with 25 cc. trichloromonoflnoromethene Castor Oil, 60 grams. trlchloromonotluoromethane Castor oil, 30 grams. (80/20 by volume), 200 grams. Borontrifluoride etherate, 2.2 cc. (80/20 by volume), 220 grams. Hexol L S-490 30 grams. 3,4-dihydro-2H-pyran-2-methyl- The borontritluoride etlierate was 3,4-dihydro-2H-pyran-2-methyl- Borontrifiuoride etherate, 3.2 cc. (3,4-dihydro-2H-pyran2-cardissolved in the castor oil (3,4-dihydro-2H-pyram2- The borontnfluorlde etherate boxylate) admixed with tetraingredient. l0 carboxylate) admixed with 2:2- was dissolved in the castor oil chlorodiglycerylphthalate di-phydroxyphenyl propane ingredient. (80/20 by weight), 200 grams. (S0/20 by weight), 220 grams. Silicone surfactant Dow 201, Dlphenylmethane dusocyanate,

1 gram. 22 grams.

Silicone surfactant Dow 201, 2.0 grams. Mixture B was added to Mixture A with vigorous stlr- 15 nng and the composition was poured into a mould. After Mixture B was added to Mixture A with vigo'rous an mductlon Penod of Seconds the foam rose for 35 stirring and the composition was poured into a mould. seconds' The foam had an Overall of lbsjcu' After an induction period of seconds the foam rose ft. and measurments of the core indicated denslties of 1.86 for 30 Seconds The foam had an overall density of 2.38 and 1.71 lb./cu. ft. The closed cell content was 83.3%. ft. and measurements of the core indicated The for req d for 10% com ression of the f am f d nsities of 1.94 and 1.95 lbs/cu. ft. The force required parallel to the dlrefllon of use a for 10% compression of the foam was 26.77 l'os./sq. in. Perpendlcular to dlrectlm of The parallel to the direction of rise and 9.32 lbs/sq. in. perforce required for 20% compression of the foam Was 1 -2 ndicular to the direction of rise. The force required lbsjsq- Parallei to the dlrecilon ns and for 20% compression of the foam was 26.70 lbs/sq. in. lbs./sq. 1n. perpegndi cularto the d1rect 10n 0f n se. CuheS parallel to the direction of rise and 10.08 lbs/sq. in. of the foam of /4 Inch slde were mamtamed bolhng perpendicular to the direction of rise. Cubes of the foam Water and were found to break down after 3 daysor" inch side were maintained in boiling water for 6 Example 36 days at which time the foam was /3 waterlogged but The following two mixtures were prepared: showed no change in shape. After an additional day of exposure in boiling water a few holes and some shrink- Mmure A Mixture]; age of the foam was noticed. The weight loss after 7 days exposure to boiling Water was 17.5%. The pH of 1111101 trimer oi2-formyl'3,4-di- Trichloromonofluoromethane, the aqueous Solution Was hydro-2H-pyran admixed with 25 cc. Examp le 38 trichloomorliofiugrtlgiethane gastloitg,3 ggrglms. 1 (80 20 yvo ume Ograms. riO grams. 3,tdihydro-ZH-pyran-Z-methyl- Borontrifluoride etherate, 2.8 cc. The fol owlng two mlxtures were prepared" (3,4-dihydro-2H-pvran-2-car- The borontrifiuoride etherate was boxylate) admixed with 2:2-didissolved in the castor oil Mixture A Mixture B phydroxyphenyl propane ingredient.

(80/20 by weight), 220 grams. 40

Diphenylmethaue diisoeyanate,

grams. Silicone surfactant Dow 201,

1.5 grams.

Mixture B was added to Mixture A with vigorous stirring. The composition was poured into a mould. After an induction period of 15 seconds the foam rose for 25 seconds. The foam had an overall density of 2.38 lbs./ cu. ft. and measurments of the core indicated densities of 1.87 and 1.81 lb./cu. ft. The force required for 10% compression of the foam was 28.4 lbs/sq. in. parallel to the direction of rise and 12.25 lbs/sq. in. perpendicular to the direction of rise. The force required for 20% compression of the foam was 29:1 lbs/sq. in. parallel to the direction of rise and 13.02 lbs./ sq. in. perpendicular to the direction of rise. The percentage change in dimensions of the foam under different conditions of temperature and relative humidity are shown in Table XXVIII.

Cubes of the foam of 4 inch side were maintained in boiling water for 7 days. The foam showed little shrinkage, contained no holes but was water-logged. The pH of the solution was 4.5.

TABLE XXVIII Percent Change in Dimensions of Foam After- 24 hours at 23 C., 50% RH.

24 hours 7 days 28 days After 28 days under the conditions specified the samples were stored for 24 hours at 23 C. and 50% relative humidity.

Trichloromonofluoromethane,

20 grams. Castor oil, 30 grams. Polyol PeP 450, 30 grams. Borontrifluoride etherate, 2.8 cc. The borontrifiuoride etherate was dissolved in the castor oil.

Mixture B was added to Mixture A with vigorous stirring. The composition was poured into a mould. After an induction period of 15 seconds the foam rose for 45 seconds. The foam had an overall density of 2.32 lbs/cu. ft. and measurements of the core indicated densities of 1.97 and 1.89 lb./cu. ft. The force required for 10% compression of the foam was 27.51 lbs/sq. in. parallel to the direction of rise and 9.29 lbs/sq. in. perpendicular to the direction of rise. The force required for 20% compression of the foam was 26.98 lbs/sq. in. parallel to the directi n of rise and 10.39 lbs/sq. in. perpendicular to the direction of rise. The percentage change in dimensions of the foam under dilferent conditions of temperature and relative humidity are shown in Table XXIX.

Example 39 The following two mixtures Were prepared:

Example 40 The 'fOIIOWiIIg two mixtures were prepared:

Mixture A Mixture B Mixture A Mixture B Aldol trimer of 2-formyl-3,4- Castor oil, 900 grams.

(proportions as in Table XXX) dihydro-ZH-pyran admixed with Pentachlorophenol, 100 grams.

trichlorornono-fluoromethane In addition there was employed (80/20 by volume), 2,500 grams. trichloromono-fluoromethane Aldol trimer of 2-formyl 3,4- Trichloromonofluoromethane. 3,4dihydro-2H-pyran-2-methyland borontrifluoride etherate parts. Diphenylmethane diisocyanate,

22 arts p Silicone surfactant Dow 201 or Dow 202, 1.5 parts.

Caster oil.

Borontrifiuoride etherate.

The borontrifluoride etherate was dissolved in the castor oil.

Mixture B was added to Mixture A with vigorous stirring and the composition poured into a mould. The composition and characteristics of three foams are shown grams (3,4-dihydro-2H-pyran-2- carboxylate) admixed with 2:2- di-p-hydroxyphenyl propane (90/10 by weight), 2,500 grams. Silicone surfactant Dow 201, 17

in quantities shown in Table Mixture B was added to Mixture A with vigorous stir- Dow 199, Dow 201, and Dow 202 are siloxane oxyalkylene copolymer type silicone surfactants. Although the exact structures are not known it is believed that in the case of surfactants L-520 and Dow 199 the siloxane and oxyalkylene portions are linked by a --SiOC-- in Table XXX. group. In the case of surfactants L530, L-531, Dow 201 TABLE XXX Trichloro- Force for 10% Force for 10% Force for 20% Force for 20% Castor Borontrimono- Induc- Rise compression, compression, compression, compression, Mixture A oil fluoride fluorotion time Density parallel to perpendicparallel to rise perpendicu- (grams) (grams) etherate methane period (sec.) (lb/sq. ft.) rise direction ular to rise direction lar to rise (ml) (cc.) (sec.) (lb/sq. in.) direction (lb./sq. in.) direction.

(lb./sq. in.) (lbJsq. in.)

Overall 463. 5 50 3. 2 30 15 45 2. 4 22. 2 12. 53 22. 32 13. 49 (Dow 202) Core 1. 91

'Preheated mould.

and Dow 202 it is believed that the siloxane and oxyalkylene portions are linked by 'a divalent hydrocarbon group.

TABLE XXXI Trichloro- Force required Force required Closed Mixture Mixture Borontrimono- Induction Rise Density Density for 10% and 20% for 10% and 20% cell A B fluoride fiuoroperiod time (overall) (core) compression compression con- (grams) (grams) etherate methane (see) (see) (lb./eu. ft.) (1b./cu. ft.) parallel to rise perpendicular to tent (m1) (ml.) direction (1b.! rise direction (persq. in.) (lb./sq. in.) cent) 36.5 (107 18. 59 (107 463.5 2.8 15 10 20 2.5 1.93 g; g 441. 5 1 e0 2. 6 15 1'5 35 2.4 1. 96 20 2 12:12 (207;) 2 350 1 54 2.9 35 5 25 2. 2 1. 7 15 (10 76 5 1 Castor oil/pentachlorophenol ratio was 3/1. I 20 grams of diphenylmethane diisocyanate added.

Percent Change in Dimensions of Foam After Exposure to Changing Temperature and Relative Humidity 23 0., 50% R.H. 100 0. (1.100% RH. -25 0.

After After After After After After After After After After After After After I After 24 7 24 7 28 28 DayS+ 24 7 28 28 Days+ 24 7 28 28 Days+ Hours Days Hours Days Days 24 Hours" Hours Days Days 24 Hours Hours Days Days 24 Hours After 28 days under the condition specified the samples were stored for 24 hours at 23 C. and 50% relative humidity.

STABILITY OF FOAM WHEN EXPOSED T0 BOILING WATER 7 After 4 days in boiling water-No change. After 7 days in boiling water-Some shrinkage, a few holes and weight loss of 14%: pH of solution, 4.8.

After 3days in boiling water-No change.

pH of solution, 5.

After 7 days in boiling waterLittle shrinkage and weight loss of 15.9%:

boiling waterweight loss of 14.3%; pH of solution,

What we claim is:

1. A foamed cellular polymeric material which is the reaction product of a foamable composition comprising (A) a dihydropyranyl group-containing compound having the dihydropyranyl groups linked by ester groups, (B) a dihydropyrauyl group-containing compound constituted by the aldol condensation product of a dihydropyran carboxaldehyde, the relative proportions of (A) and (B) lying within the range of 10 to l and 1 to 10 by weight, (C) 0.005% to 2.0%, by weight of the composition, of a catalyst capable of promoting the polymerization reaction of (A) and (B), and (D) 2% to 30%, by weight of the composition, of a foaming agent vaporizing at the temperature of the polymerization reaction.

2. A foamed cellular polymeric material as claimed in claim 1 wherein the foamable composition contains up to 30% by weight of a material reactive with the ethylenic double bonds of its dihydropyranyl ingredients.

3. A foamed cellular polymeric material as claimed in claim 2 wherein the material reactive with the ethylenic double bonds of the dihydropyranyl ingredients of the foamable composition is a member selected from the group consisting of polyhydric phenols, chlorinated phenols, polyhydric alcohols, epoxidized materials, a,,B-monoethylenically unsaturated compounds and organic diisocyanates.

4. A foamed cellular polymeric material as claimed in claim 1 wherein the ingredient of the foamable composition having its dihydropyranyl groups linked by ester groups is 3,4-dihydro-2H-pyran-2-methyl-(3,4-dihydro- 2H-pyran-2-carb oxylate) 5. A foamed cellular polymeric material as claimed in claim 1 wherein the ingredient of the foamable composition which is the aldol condensation product of a dihydro- 38 pyran carboxaldehyde is the trimeric aldol condensation product of 2-formyl-3,4-dihydro-2H-pyrau.

6. A foamed cellular polymeric material as claimed in claim 1 wherein the catalyst ingredient of the foamable composition is a member selected from the group consisting of boron trifluoride etherate, boron trifluoride dihydrate and mixtures of fluoboric acid and fluosilicic acid.

7. A process which comprises mixing, essentially (A) a dihydropyranyl group-containing compound having the dihydropyranyl groups linked by ester groups, (B) a dihydropyranyl group-containing compound constituted by the aldol condensation product of a dihydropyran carboxaldehyde, the relative proportions of (A) and (B) lying within the range of 10 to 1 and 1 to 10 by weight, (C) a catalyst capable of promoting the polymerization reaction of (A) and (B), and (D) a foaming agent vaporizing at the temperature of the polymerization re action, and allowing the mixture naturally to self-expand into a foamed cellular polymeric material.

8. A process as claimed in claim 7 wherein there is incorporated into the expandable mixture a material reactive with the ethylenic double bonds of the dihydropyranyl compounds.

References Cited UNITED STATES PATENTS 3/ 1967 Bowering et a1. 260-25 3/ 1967 Graham 260-25 

